Process for making fibrous structures

ABSTRACT

Processes for making fibrous structures and more particularly processes for making fibrous structures comprising filaments are provided.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of prior U.S. Pat. No. 15,891,726filed Feb. 8, 2018; which is a continuation of U.S. application Ser. No.14/475,699 filed Sep. 5, 2014, now U.S. Pat. No. 9,926,648; which is acontinuation of U.S. application Ser. No. 12,170,575 filed Jul. 10,2008, now U.S. Pat. No. 8,852,474; which claims the benefit of U.S.Provisional Application No. 60/959,885, filed Jul. 17, 2007.

FIELD OF THE INVENTION

The present invention relates to processes for making fibrous structuresand more particularly to processes for making fibrous structurescomprising filaments.

BACKGROUND OF THE INVENTION

Processes for making fibrous structures comprising filaments are knownin the art. An example of such a known process is a co-form process.

Known co-form processes utilize a knife-edge die that comprisesfilament-forming holes. The filaments produced by the filament-formingholes are contacted after exiting by air. The air contacts the filamentsat an angle of 30° to less than 90°, not parallel to or substantiallyparallel to the filament produced from the filament-forming holes.

The problem with current processes for making fibrous structures,especially processes that utilize knife-edge dies, is that the fibrousstructures comprise filaments having a distribution of average filamentdiameters that does not optimize the properties, for example absorbencyproperties (such as absorption capacity and/or rate of absorption) ofthe fibrous structures.

Accordingly, there is a need for a process for making fibrousstructures, especially fibrous structure that comprise filaments, thatprovide improved properties compared to fibrous structures produced byknown processes for making fibrous structures, especially processes thatutilize knife-edge dies.

SUMMARY OF THE INVENTION

The present invention solves the problem identified above by providing aprocess for making fibrous structures, especially fibrous structure thatcomprise filaments, that exhibit improved properties compared to fibrousstructure produced by known processes for making fibrous structures,especially processes that utilize knife-edge dies.

In one example of the present invention, a process for making a fibrousstructure, the process comprising the steps of:

a. providing a die comprising one or more filament-forming holes,wherein one or more fluid-releasing holes are associated with onefilament-forming hole such that a fluid exiting the fluid-releasing holeis parallel or substantially parallel to an exterior surface of afilament exiting the filament-forming hole;

b. supplying at least a first polymer to the die;

c. producing a plurality of filaments comprising the first polymer fromthe die;

d. combining the filaments with solid additives to form a mixture; and

e. collecting the mixture on a collection device to produce a fibrousstructure; is provided.

In another example of the present invention, a process for making afibrous structure, the process comprising the steps of:

a. providing a die comprising one or more filament-forming holes,wherein one or more fluid-releasing holes are associated with onefilament-forming hole such that a fluid exiting the fluid-releasing holeis parallel or substantially parallel to an exterior surface of afilament exiting the filament-forming hole;

b. supplying a polyolefin polymer to the die;

c. producing a plurality of filaments comprising the polyolefin polymerfrom the die;

d. combining the filaments with wood pulp fibers to form a mixture; and

e. collecting the mixture on a collection device to produce a fibrousstructure; is provided.

In yet another example of the present invention, a fibrous structuremade by a process according to the present invention is provided.

Accordingly, the present invention provides a process for making fibrousstructures, especially fibrous structure that comprise filaments, thatexhibit improved properties compared to fibrous structure produced byknown processes for making fibrous structures, especially processes thatutilize knife-edge dies.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a Pore Volume Distribution graph of various fibrousstructures, including a fibrous structure according to the presentinvention, showing the Ending Pore Radius of from 1 μm to 1000 μm andthe Capacity of Water in Pores;

FIG. 2 is a Pore Volume Distribution graph of various fibrousstructures, including a fibrous structure according to the presentinvention, showing the Ending Pore Radius of from 1 μm to 300 μm and theCapacity of Water in Pores;

FIG. 3 is a schematic representation of an example of a fibrousstructure according to the present invention;

FIG. 4 is a schematic, cross-sectional representation of FIG. 3 takenalong line 4-4;

FIG. 5 is a schematic representation of another example of a fibrousstructure according to the present invention;

FIG. 6 is a schematic, cross-sectional representation of another exampleof a fibrous structure according to the present invention;

FIG. 7 is a schematic, cross-sectional representation of another exampleof a fibrous structure according to the present invention;

FIG. 8 is a schematic representation of another example of a fibrousstructure in roll form according to the present invention;

FIG. 9 is a schematic representation of another example of a fibrousstructure;

FIG. 10 is a schematic representation of an example of a process formaking a fibrous structure according to the present invention;

FIG. 11 is a schematic representation of an example of afilament-forming hole and fluid-releasing hole from a suitable dieuseful in making a fibrous structure according to the present invention;

FIG. 12 is a scanning electromicrograph of a fibrous structure made by aknown die;

FIG. 13 is a scanning electromicrograph of a fibrous structure made by adie according to the present invention;

FIG. 14 is a schematic representation of an example of a solid additivespreader useful in the processes of the present invention;

FIG. 15 is a schematic representation of another example of a solidadditive spreader useful in the processes of the present invention;

FIG. 16 is a diagram of a support rack utilized in the HFS and VFS TestMethods described herein;

FIG. 17 is a diagram of a support rack cover utilized in the HFS and VFSTest Methods described herein.

DETAILED DESCRIPTION OF THE INVENTION Definitions

“Fibrous structure” as used herein means a structure that comprises oneor more filaments and/or fibers. In one example, a fibrous structureaccording to the present invention means an orderly arrangement offilaments and/or fibers within a structure in order to perform afunction. Nonlimiting examples of fibrous structures of the presentinvention include paper, fabrics (including woven, knitted, andnon-woven), and absorbent pads (for example for diapers or femininehygiene products).

Nonlimiting examples of processes for making fibrous structures includeknown wet-laid papermaking processes and air-laid papermaking processes.Such processes typically include steps of preparing a fiber compositionin the form of a suspension in a medium, either wet, more specificallyaqueous medium, or dry, more specifically gaseous, i.e. with air asmedium. The aqueous medium used for wet-laid processes is oftentimesreferred to as a fiber slurry. The fibrous slurry is then used todeposit a plurality of fibers onto a forming wire or belt such that anembryonic fibrous structure is formed, after which drying and/or bondingthe fibers together results in a fibrous structure. Further processingthe fibrous structure may be carried out such that a finished fibrousstructure is formed. For example, in typical papermaking processes, thefinished fibrous structure is the fibrous structure that is wound on thereel at the end of papermaking, and may subsequently be converted into afinished product, e.g. a sanitary tissue product.

The fibrous structures of the present invention may be homogeneous ormay be layered. If layered, the fibrous structures may comprise at leasttwo and/or at least three and/or at least four and/or at least fivelayers.

The fibrous structures of the present invention may be co-formed fibrousstructures.

“Co-formed fibrous structure” as used herein means that the fibrousstructure comprises a mixture of at least two different materialswherein at least one of the materials comprises a filament, such as apolypropylene filament, and at least one other material, different fromthe first material, comprises a solid additive, such as a fiber and/or aparticulate. In one example, a co-formed fibrous structure comprisessolid additives, such as fibers, such as wood pulp fibers, andfilaments, such as polypropylene filaments.

“Solid additive” as used herein means a fiber and/or a particulate.

“Particulate” as used herein means a granular substance or powder.

“Fiber” and/or “Filament” as used herein means an elongate particulatehaving an apparent length greatly exceeding its apparent width, i.e. alength to diameter ratio of at least about 10. For purposes of thepresent invention, a “fiber” is an elongate particulate as describedabove that exhibits a length of less than 5.08 cm (2 in.) and a“filament” is an elongate particulate as described above that exhibits alength of greater than or equal to 5.08 cm (2 in.).

Fibers are typically considered discontinuous in nature. Nonlimitingexamples of fibers include wood pulp fibers and synthetic staple fiberssuch as polyester fibers.

Filaments are typically considered continuous or substantiallycontinuous in nature. Filaments are relatively longer than fibers.Nonlimiting examples of filaments include meltblown and/or spunbondfilaments. Nonlimiting examples of materials that can be spun intofilaments include natural polymers, such as starch, starch derivatives,cellulose and cellulose derivatives, hemicellulose, hemicellulosederivatives, and synthetic polymers including, but not limited topolyvinyl alcohol filaments and/or polyvinyl alcohol derivativefilaments, and thermoplastic polymer filaments, such as polyesters,nylons, polyolefins such as polypropylene filaments, polyethylenefilaments, and biodegradable or compostable thermoplastic fibers such aspolylactic acid filaments, polyhydroxyalkanoate filaments andpolycaprolactone filaments. The filaments may be monocomponent ormulticomponent, such as bicomponent filaments.

In one example of the present invention, “fiber” refers to papermakingfibers. Papermaking fibers useful in the present invention includecellulosic fibers commonly known as wood pulp fibers. Applicable woodpulps include chemical pulps, such as Kraft, sulfite, and sulfate pulps,as well as mechanical pulps including, for example, groundwood,thermomechanical pulp and chemically modified thermomechanical pulp.Chemical pulps, however, may be preferred since they impart a superiortactile sense of softness to tissue sheets made therefrom. Pulps derivedfrom both deciduous trees (hereinafter, also referred to as “hardwood”)and coniferous trees (hereinafter, also referred to as “softwood”) maybe utilized. The hardwood and softwood fibers can be blended, oralternatively, can be deposited in layers to provide a stratified web.U.S. Pat. Nos. 4,300,981 and 3,994,771 are incorporated herein byreference for the purpose of disclosing layering of hardwood andsoftwood fibers. Also applicable to the present invention are fibersderived from recycled paper, which may contain any or all of the abovecategories as well as other non-fibrous materials such as fillers andadhesives used to facilitate the original papermaking.

In addition to the various wood pulp fibers, other cellulosic fiberssuch as cotton linters, rayon, lyocell and bagasse can be used in thisinvention. Other sources of cellulose in the form of fibers or capableof being spun into fibers include grasses and grain sources.

“Sanitary tissue product” as used herein means a soft, low density (i.e.< about 0.15 g/cm3) web useful as a wiping implement for post-urinaryand post-bowel movement cleaning (toilet tissue), forotorhinolaryngological discharges (facial tissue), and multi-functionalabsorbent and cleaning uses (absorbent towels). The sanitary tissueproduct may be convolutedly wound upon itself about a core or without acore to form a sanitary tissue product roll.

In one example, the sanitary tissue product of the present inventioncomprises a fibrous structure according to the present invention.

The sanitary tissue products of the present invention may exhibit abasis weight between about 10 g/m² to about 120 g/m² and/or from about15 g/m² to about 110 g/m² and/or from about 20 g/m² to about 100 g/m²and/or from about 30 to 90 g/m². In addition, the sanitary tissueproduct of the present invention may exhibit a basis weight betweenabout 40 g/m² to about 120 g/m² and/or from about 50 g/m² to about 110g/m² and/or from about 55 g/m² to about 105 g/m² and/or from about 60 to100 g/m².

The sanitary tissue products of the present invention may exhibit atotal dry tensile strength of greater than about 59 g/cm (150 g/in)and/or from about 78 g/cm (200 g/in) to about 394 g/cm (1000 g/in)and/or from about 98 g/cm (250 g/in) to about 335 g/cm (850 g/in). Inaddition, the sanitary tissue product of the present invention mayexhibit a total dry tensile strength of greater than about 196 g/cm (500g/in) and/or from about 196 g/cm (500 g/in) to about 394 g/cm (1000g/in) and/or from about 216 g/cm (550 g/in) to about 335 g/cm (850 g/in)and/or from about 236 g/cm (600 g/in) to about 315 g/cm (800 g/in). Inone example, the sanitary tissue product exhibits a total dry tensilestrength of less than about 394 g/cm (1000 g/in) and/or less than about335 g/cm (850 g/in).

In another example, the sanitary tissue products of the presentinvention may exhibit a total dry tensile strength of greater than about196 g/cm (500 g/in) and/or greater than about 236 g/cm (600 g/in) and/orgreater than about 276 g/cm (700 g/in) and/or greater than about 315g/cm (800 g/in) and/or greater than about 354 g/cm (900 g/in) and/orgreater than about 394 g/cm (1000 g/in) and/or from about 315 g/cm (800g/in) to about 1968 g/cm (5000 g/in) and/or from about 354 g/cm (900g/in) to about 1181 g/cm (3000 g/in) and/or from about 354 g/cm (900g/in) to about 984 g/cm (2500 g/in) and/or from about 394 g/cm (1000g/in) to about 787 g/cm (2000 g/in).

The sanitary tissue products of the present invention may exhibit aninitial total wet tensile strength of less than about 78 g/cm (200 g/in)and/or less than about 59 g/cm (150 g/in) and/or less than about 39 g/cm(100 g/in) and/or less than about 29 g/cm (75 g/in).

The sanitary tissue products of the present invention may exhibit aninitial total wet tensile strength of greater than about 118 g/cm (300g/in) and/or greater than about 157 g/cm (400 g/in) and/or greater thanabout 196 g/cm (500 g/in) and/or greater than about 236 g/cm (600 g/in)and/or greater than about 276 g/cm (700 g/in) and/or greater than about315 g/cm (800 g/in) and/or greater than about 354 g/cm (900 g/in) and/orgreater than about 394 g/cm (1000 g/in) and/or from about 118 g/cm (300g/in) to about 1968 g/cm (5000 g/in) and/or from about 157 g/cm (400g/in) to about 1181 g/cm (3000 g/in) and/or from about 196 g/cm (500g/in) to about 984 g/cm (2500 g/in) and/or from about 196 g/cm (500g/in) to about 787 g/cm (2000 g/in) and/or from about 196 g/cm (500g/in) to about 591 g/cm (1500 g/in).

The sanitary tissue products of the present invention may exhibit adensity (measured at 95 g/in²) of less than about 0.60 g/cm³ and/or lessthan about 0.30 g/cm³ and/or less than about 0.20 g/cm³ and/or less thanabout 0.10 g/cm³ and/or less than about 0.07 g/cm³ and/or less thanabout 0.05 g/cm³ and/or from about 0.01 g/cm³ to about 0.20 g/cm³ and/orfrom about 0.02 g/cm³ to about 0.10 g/cm³.

The sanitary tissue products of the present invention may exhibit atotal absorptive capacity of according to the Horizontal Full Sheet(HFS) Test Method described herein of greater than about 10 g/g and/orgreater than about 12 g/g and/or greater than about 15 g/g and/or fromabout 15 g/g to about 50 g/g and/or to about 40 g/g and/or to about 30g/g.

The sanitary tissue products of the present invention may exhibit aVertical Full Sheet (VFS) value as determined by the Vertical Full Sheet(VFS) Test Method described herein of greater than about 5 g/g and/orgreater than about 7 g/g and/or greater than about 9 g/g and/or fromabout 9 g/g to about 30 g/g and/or to about 25 g/g and/or to about 20g/g and/or to about 17 g/g.

The sanitary tissue products of the present invention may be in the formof sanitary tissue product rolls. Such sanitary tissue product rolls maycomprise a plurality of connected, but perforated sheets of fibrousstructure, that are separably dispensable from adjacent sheets. In oneexample, one or more ends of the roll of sanitary tissue product maycomprise an adhesive and/or dry strength agent to mitigate the loss offibers, especially wood pulp fibers from the ends of the roll ofsanitary tissue product.

The sanitary tissue products of the present invention may comprisesadditives such as softening agents, temporary wet strength agents,permanent wet strength agents, bulk softening agents, lotions,silicones, wetting agents, latexes, especially surface-pattern-appliedlatexes, dry strength agents such as carboxymethylcellulose and starch,and other types of additives suitable for inclusion in and/or onsanitary tissue products.

“Weight average molecular weight” as used herein means the weightaverage molecular weight as determined using gel permeationchromatography according to the protocol found in Colloids and SurfacesA. Physico Chemical & Engineering Aspects, Vol. 162, 2000, pg. 107-121.

“Basis Weight” as used herein is the weight per unit area of a samplereported in lbs/3000 ft² or g/m².

“Machine Direction” or “MD” as used herein means the direction parallelto the flow of the fibrous structure through the fibrous structuremaking machine and/or sanitary tissue product manufacturing equipment.

“Cross Machine Direction” or “CD” as used herein means the directionparallel to the width of the fibrous structure making machine and/orsanitary tissue product manufacturing equipment and perpendicular to themachine direction.

“Ply” as used herein means an individual, integral fibrous structure.

“Plies” as used herein means two or more individual, integral fibrousstructures disposed in a substantially contiguous, face-to-facerelationship with one another, forming a multi-ply fibrous structureand/or multi-ply sanitary tissue product. It is also contemplated thatan individual, integral fibrous structure can effectively form amulti-ply fibrous structure, for example, by being folded on itself.

“Total Pore Volume” as used herein means the sum of the fluid holdingvoid volume in each pore range from 1 μm to 1000 μm radii as measuredaccording to the Pore Volume Test Method described herein.

“Pore Volume Distribution” as used herein means the distribution offluid holding void volume as a function of pore radius. The Pore VolumeDistribution of a fibrous structure is measured according to the PoreVolume Test Method described herein.

As used herein, the articles “a” and “an” when used herein, for example,“an anionic surfactant” or “a fiber” is understood to mean one or moreof the material that is claimed or described.

All percentages and ratios are calculated by weight unless otherwiseindicated. All percentages and ratios are calculated based on the totalcomposition unless otherwise indicated.

Unless otherwise noted, all component or composition levels are inreference to the active level of that component or composition, and areexclusive of impurities, for example, residual solvents or by-products,which may be present in commercially available sources.

Fibrous Structure

It has surprisingly been found that the fibrous structures of thepresent invention exhibit a pore volume distribution unlike pore volumedistributions of other known fibrous structures.

The fibrous structures of the present invention may comprise a pluralityof filaments, a plurality of solid additives, such as fibers, and amixture of filaments and solid additives.

As shown in FIGS. 1 and 2, examples of fibrous structures according tothe present invention as represented by plots A and B exhibit a porevolume distribution such that greater than about 40% of the total porevolume present in the fibrous structure exists in pores of radii of fromabout 121 μm to about 200 μm and/or greater than about 50% of the totalpore volume present in the fibrous structure exists in pores of radii offrom about 101 μm to about 200 μm. The ranges of 101 μm to 200 μm and121 μm to 200 μm are explicitly identified on the graph of FIG. 2. Itshould be noted that the value for the ending pore radius for the rangeof 101 μm to 120 μm is plotted at the ending pore radius; namely, 120μm. A similar result is shown on FIG. 2 for the value for the endingpore radius for the range of 121 μm to 140 μm, where the value isplotted at the ending pore radius; namely, 140 μm. This data is alsosupported by the values present in Table 1 below.

Such fibrous structures have been found to exhibit consumer-recognizablebeneficial absorbent capacity. In one example, the fibrous structurescomprise a plurality of solid additives, for example fibers. In anotherexample, the fibrous structures comprise a plurality of filaments. Inyet another example, the fibrous structures comprise a mixture offilaments and solid additives, such as fibers.

As shown in FIG. 2, the examples of fibrous structures according to thepresent invention as represented by plots A and B may exhibit a bi-modalpore volume distribution such that the fibrous structure exhibits a porevolume distribution such that the greater than about 40% of the totalpore volume present in the fibrous structure exists in pores of radii offrom about 121 μm to about 200 μm and greater than about 2% and/orgreater than about 5% and/or greater than about 10% of the total porevolume present in the fibrous structure exists in pores of radii of lessthan about 100 μm and/or less than about 80 μm and/or less than about 50μm and/or from about 1 μm to about 100 μm and/or from about 5 μm toabout 75 μm and/or 10 μm to about 50 μm.

A fibrous structure according to the present invention exhibiting abi-modal pore volume distribution as described above provides beneficialabsorbent capacity and absorbent rate as a result of the larger radiipores and beneficial surface drying as a result of the smaller radiipores.

FIGS. 3 and 4 show schematic representations of an example of a fibrousstructure in accordance with the present invention. As shown in FIGS. 3and 4, the fibrous structure 10 may be a co-formed fibrous structure.The fibrous structure 10 comprises a plurality of filaments 12, such aspolypropylene fibers, and a plurality of solid additives, such as woodpulp fibers 14. The filaments 12 may be randomly arranged as a result ofthe process by which they are spun and/or formed into the fibrousstructure 10. The wood pulp fibers 14, may be randomly dispersedthroughout the fibrous structure 10 in the x-y plane. The wood pulpfibers 14 may be non-randomly dispersed throughout the fibrous structurein the z-direction. In one example (not shown), the wood pulp fibers 14are present at a higher concentration on one or more of the exterior,x-y plane surfaces than within the fibrous structure along thez-direction.

As shown in FIG. 5, another example of a fibrous structure in accordancewith the present invention is a layered fibrous structure 10′. Thelayered fibrous structure 10′ comprises a first layer 16 comprising aplurality of filaments 12, such as polypropylene filaments, and aplurality of solid additives, in this example wood pulp fibers 14. Thelayered fibrous structure 10′ further comprises a second layer 18comprising a plurality of filaments 20, such as polypropylene filaments.In one example, the first and second layers 16, 18, respectively, aresharply defined zones of concentration of the filaments and/or solidadditives. The plurality of filaments 20 may be deposited directly ontoa surface of the first layer 16 to form a layered fibrous structure thatcomprises the first and second layers 16, 18, respectively.

Further, the layered fibrous structure 10′ may comprise a third layer22, as shown in FIG. 5. The third layer 22 may comprise a plurality offilaments 24, which may be the same or different from the filaments 20in the second and/or first layers 18, 16. As a result of the addition ofthe third layer 22, the first layer 16 is positioned, for examplesandwiched, between the second layer 18 and the third layer 22. Theplurality of filaments 24 may be deposited directly onto a surface ofthe first layer 16, opposite from the second layer, to form the layeredfibrous structure 10′ that comprises the first, second and third layers16, 18, 22, respectively.

As shown in FIG. 6, a cross-sectional schematic representation ofanother example of a fibrous structure in accordance with the presentinvention comprising a layered fibrous structure 10″ is provided. Thelayered fibrous structure 10″ comprises a first layer 26, a second layer28 and optionally a third layer 30. The first layer 26 comprises aplurality of filaments 12, such as polypropylene filaments, and aplurality of solid additives, such as wood pulp fibers 14. The secondlayer 28 may comprise any suitable filaments, solid additives and/orpolymeric films. In one example, the second layer 28 comprises aplurality of filaments 34. In one example, the filaments 34 comprise apolymer selected from the group consisting of: polysaccharides,polysaccharide derivatives, polyvinylalcohol, polyvinylalcoholderivatives and mixtures thereof.

In another example of a fibrous structure in accordance with the presentinvention, instead of being layers of fibrous structure 10″, thematerial forming layers 26, 28 and 30, may be in the form of plieswherein two or more of the plies may be combined to form a fibrousstructure. The plies may be bonded together, such as by thermal bondingand/or adhesive bonding, to form a multi-ply fibrous structure.

Another example of a fibrous structure of the present invention inaccordance with the present invention is shown in FIG. 7. The fibrousstructure 10′″ may comprise two or more plies, wherein one ply 36comprises any suitable fibrous structure in accordance with the presentinvention, for example fibrous structure 10 as shown and described inFIGS. 3 and 4 and another ply 38 comprising any suitable fibrousstructure, for example a fibrous structure comprising filaments 40, suchas polypropylene filaments. The fibrous structure of ply 38 may be inthe form of a net and/or mesh and/or other structure that comprisespores that expose one or more portions of the fibrous structure 10 to anexternal environment and/or at least to liquids that may come intocontact, at least initially, with the fibrous structure of ply 38. Inaddition to ply 38, the fibrous structure 10′″ may further comprise ply42. Ply 42 may comprise a fibrous structure comprising filaments 44,such as polypropylene filaments, and may be the same or different fromthe fibrous structure of ply 38.

Two or more of the plies 36, 38 and 42 may be bonded together, such asby thermal bonding and/or adhesive bonding, to form a multi-ply fibrousstructure. After a bonding operation, especially a thermal bondingoperation, it may be difficult to distinguish the plies of the fibrousstructure 10′″ and the fibrous structure 10′″ may visually and/orphysically be a similar to a layered fibrous structure in that one wouldhave difficulty separating the once individual plies from each other. Inone example, ply 36 may comprise a fibrous structure that exhibits abasis weight of at least about 15 g/m² and/or at least about 20 g/m²and/or at least about 25 g/m² and/or at least about 30 g/m² up to about120 g/m² and/or 100 g/m² and/or 80 g/m² and/or 60 g/m² and the plies 38and 42, when present, independently and individually, may comprisefibrous structures that exhibit basis weights of less than about 10 g/m²and/or less than about 7 g/m² and/or less than about 5 g/m² and/or lessthan about 3 g/m² and/or less than about 2 g/m² and/or to about 0 g/m²and/or 0.5 g/m².

Plies 38 and 42, when present, may help retain the solid additives, inthis case the wood pulp fibers 14, on and/or within the fibrousstructure of ply 36 thus reducing lint and/or dust (as compared to asingle-ply fibrous structure comprising the fibrous structure of ply 36without the plies 38 and 42) resulting from the wood pulp fibers 14becoming free from the fibrous structure of ply 36.

The fibrous structures of the present invention may comprise anysuitable amount of filaments and any suitable amount of solid additives.For example, the fibrous structures may comprise from about 10% to about70% and/or from about 20% to about 60% and/or from about 30% to about50% by dry weight of the fibrous structure of filaments and from about90% to about 30% and/or from about 80% to about 40% and/or from about70% to about 50% by dry weight of the fibrous structure of solidadditives, such as wood pulp fibers.

The filaments and solid additives of the present invention may bepresent in fibrous structures according to the present invention atweight ratios of filaments to solid additives of from at least about 1:1and/or at least about 1:1.5 and/or at least about 1:2 and/or at leastabout 1:2.5 and/or at least about 1:3 and/or at least about 1:4 and/orat least about 1:5 and/or at least about 1:7 and/or at least about 1:10.

The fibrous structures of the present invention and/or any sanitarytissue products comprising such fibrous structures may be subjected toany post-processing operations such as embossing operations, printingoperations, tuft-generating operations, thermal bonding operations,ultrasonic bonding operations, perforating operations, surface treatmentoperations such as application of lotions, silicones and/or othermaterials and mixtures thereof.

Any hydrophobic or non-hydrophilic materials within the fibrousstructure, such as polypropylene filaments, may be surface treatedand/or melt treated with a hydrophilic modifier. Nonlimiting examples ofsurface treating hydrophilic modifiers include surfactants, such asTriton X-100. Nonlimiting examples of melt treating hydrophilicmodifiers that are added to the melt, such as the polypropylene melt,prior to spinning filaments, include hydrophilic modifying meltadditives such as VW351 commercially available from Polyvel, Inc. andIrgasurf commercially available from Ciba. The hydrophilic modifier maybe associated with the hydrophobic or non-hydrophilic material at anysuitable level known in the art. In one example, the hydrophilicmodifier is associated with the hydrophobic or non-hydrophilic materialat a level of less than about 20% and/or less than about 15% and/or lessthan about 10% and/or less than about 5% and/or less than about 3% toabout 0% by dry weight of the hydrophobic or non-hydrophilic material.

The fibrous structures of the present invention may include optionaladditives, each, when present, at individual levels of from about 0%and/or from about 0.01% and/or from about 0.1% and/or from about 1%and/or from about 2% to about 95% and/or to about 80% and/or to about50% and/or to about 30% and/or to about 20% by dry weight of the fibrousstructure. Nonlimiting examples of optional additives include permanentwet strength agents, temporary wet strength agents, dry strength agentssuch as carboxymethylcellulose and/or starch, softening agents, lintreducing agents, opacity increasing agents, wetting agents, odorabsorbing agents, perfumes, temperature indicating agents, color agents,dyes, osmotic materials, microbial growth detection agents,antibacterial agents and mixtures thereof.

The fibrous structure of the present invention may itself be a sanitarytissue product. It may be convolutedly wound about a core to form aroll. It may be combined with one or more other fibrous structures as aply to form a multi-ply sanitary tissue product. In one example, aco-formed fibrous structure of the present invention may be convolutedlywound about a core to form a roll of co-formed sanitary tissue product.The rolls of sanitary tissue products may also be coreless.

As shown in FIG. 8, a fibrous structure roll 46 comprising a fibrousstructure, such as a fibrous structure according to the presentinvention, comprises end edges 48, 50. At least one of the end edges 48,50 comprises a bond region 52. The bond region 52 may comprise aplurality of bond subregions (not shown) that are present at a frequencyof at least about 10 and/or at least about 50 and/or at least about 100and/or at least about 200 per inch, such as dots per inch (dpi). In oneexample, the bond region 52 may cover the entire or substantially theentire surface area of the end edge 48. In one example, the bond region52 comprises greater than about 20% and/or greater than about 25% and/orgreater than about 30% and/or greater than about 50% of the totalsurface area of the end edge 48. In one example, the bond region 52 is afilm that comprises the entire or substantially entire total surfacearea of the end edge 48. In another example, the bond region 52 ispresent on a non-lotioned fibrous structure.

The bond region 52 may comprise a bonding agent selected from chemicalagents and/or mechanical agents. Nonlimiting examples of chemical agentsinclude dry strength agents and wet strength agents and mixturesthereof. The mechanical agents may be in the form of a liquid and/or asolid. A liquid mechanical agent may be an oil. A solid mechanical agentmay be a wax.

The bond region 52 may comprise different types of bonding agents and/orbonding agents that are chemically different from the filaments and/orfibers present in the fibrous structure. In one example, the materialcomprises a bonding agent, such as a dry strength resin such as apolysaccharide and/or a polysaccharide derivative and temporary andpermanent wet strength resins. Nonlimiting examples of suitable bondingagents include latex dispersions, polyvinyl alcohol, Parez®, Kymene®,carboxymethylcellulose and starch.

As shown in FIG. 9, a fibrous structure 54 in accordance with thepresent invention may comprise edges 56, 58, 60, 62. One or more of theedges 56, 58, 60, 62 may comprise a bond region 64. The bond region 64may extend inwardly from the edge 56, for example less than about 1 cmand/or less than about 0.5 cm. Any of the edges may comprise such a bondregion. The bond region 64 may comprise a plurality of bond subregions(not shown) that are present at a frequency of at least 10 and/or atleast 50 and/or at least 100 and/or at least 200 per inch, such as dotsper inch (dpi). The bond region 64 may comprise a material chemicallydifferent from the filaments and/or fibers present in the fibrousstructure. In one example, the material comprises a bonding agent, suchas a dry strength resin such as a polysaccharide and/or a polysaccharidederivative. Nonlimiting examples of suitable bonding agents includecarboxymethylcellulose and starch.

To further illustrate the fibrous structures of the present invention,Table 1 sets forth the average pore volume distributions of known and/orcommercially available fibrous structures and a fibrous structure inaccordance with the present invention.

TABLE 1 Pore Huggies ® Concert LBAL- Invention Invention Radius WashEBT.055.1010 DUNI Example Example (μm) Huggies ® Cloth Duramax TBALembossed Bounty ® A B 1 0 0 0 0 0 0 0 0 2.5 19.25 29.6 32.4 33.65 34.431.1 19.55 15.85 5 11.65 16.1 17.85 18.1 18.25 17.6 12.4 7.95 10 11.712.6 28.5 14.4 14.75 32.8 10.35 6.45 15 7.95 7.05 101.7 8.65 8.5 52.36.45 3.2 20 7.15 4.65 62.7 6.45 6.4 36.7 3.8 2.45 30 31.35 6.45 91.559.1 9.55 54 7.1 3.65 40 110.4 5.5 82.1 26.3 127.25 47.8 6.4 3.4 50133.05 6.5 77.35 65.95 71.4 43.6 6.5 4.6 60 200.1 96.55 70.5 74.7 59.9538.9 7.5 6.55 70 302.45 144.85 61.65 70.25 69.05 36.3 13.85 11.3 80336.9 132.35 56.05 102.05 95.05 33.9 150.85 63.15 90 250.9 150.8 49.3174.05 150.1 33 137.5 128 100 160.15 162.8 48.3 293 232.9 32.2 143.35129.25 120 172.8 394.1 95.6 693.4 464.15 64.7 359.75 306.05 140 85.1451.7 89.5 162.55 176.45 68.5 578.8 521.95 160 54 505.45 76.6 19.35 49.674.8 485.85 613.35 180 37.3 509.7 63.45 10.15 24.3 78.5 257.65 243.3 20030.15 450.95 50 8.2 18.55 89.2 108.7 69.15 225 28.2 409.15 51.6 8.518.95 134.4 56.15 32.55 250 22.85 245.2 44 7.5 16.25 149.8 32.3 20.6 27522.15 144.1 40.25 2.7 14.9 157.9 22.75 13.75 300 18.4 101.3 35.95 10.0513.75 125.7 24.6 7.9 350 29.95 153.2 60.7 10.9 25.4 145 41.95 24.45 40024.25 141.7 59.25 9.65 26.65 52.4 40.55 17.55 500 45.6 271.15 266.4515.75 116.85 56 51.45 31.05 600 34.3 230.95 291.9 14.5 71.3 23.9 33.4527.95 800 46.65 261.6 162.4 24.3 34.25 34.9 45.35 32.6 1000 38.75 112.5529.15 24.9 30.35 24.9 34.6 25.55 Total 2273.45 5158.6 2196.75 1919.051999.25 1770.8 2699.5 2373.55 101-200 μm 16.7% 44.8% 17.1% 46.6% 36.7%21.2% 66.3% 73.9% 121-200 μm 9.1% 37.2% 12.7% 10.4% 13.5% 17.6% 53.0%61.0%

The fibrous structures of the present invention may exhibit a uniquecombination of fibrous structure properties that do not exist in knownfibrous structures. For example, the fibrous structures may exhibit aVFS of greater than about 11 g/g and/or greater than about 12 g/g and/orgreater than about 13 g/g and/or greater than about 14 g/g and/or lessthan about 50 g/g and/or less than about 40 g/g and/or less than about30 g/g and/or less than about 20 g/g and/or from about 11 g/g to about50 g/g and/or from about 11 g/g to about 40 g/g and/or from about 11 g/gto about 30 g/g and/or from about 11 g/g to about 20 g/g.

In addition to the VFS property, the fibrous structures of the presentinvention may exhibit a Dry CD Tensile Modulus of less than about 1500g/cm and/or less than about 1400 g/cm and/or less than about 1300 g/cmand/or less than about 1100 g/cm and/or less than about 1000 g/cm and/orless than about 800 g/cm and/or greater than about 50 g/cm and/orgreater than about 100 g/cm and/or greater than about 300 g/cm and/orfrom about 50 g/cm to about 1500 g/cm and/or from about 100 g/cm toabout 1400 g/cm and/or from about 100 g/cm to about 1300 g/cm.

In addition to the VFS property and/or the Dry CD Tensile Modulusproperty, the fibrous structures of the present invention may exhibit aWet CD TEA of greater than about 35 (g in)/in² and/or greater than about50 (g· in)/in² and/or greater than about 75 (g· in)/in² and/or greaterthan about 90 (g· in)/in² and/or greater than about 150 (g· in)/in²and/or greater than about 175 (g· in)/in² and/or less than about 500 (g·in)/in² and/or less than about 400 (g· in)/in² and/or less than about350 (g· in)/in² and/or less than about 300 (g· in)/in² and/or from about35 (g· in)/in² to about 500 (g· in)/in² and/or from about 35 (g· in)/in²to about 400 (g· in)/in² and/or from about 50 (g· in)/in² to about 350(g· in)/in² and/or from about 75 (g· in)/in² to about 300 (g· in)/in².

In addition to the VFS property and/or the Dry CD Tensile Modulusproperty and/or the Wet CD TEA, the fibrous structures of the presentinvention may exhibit a Wet MD TEA of greater than about 40 (g· in)/in²and/or greater than about 50 (g· in)/in² and/or greater than about 75(g· in)/in² and/or greater than about 90 (g· in)/in² and/or greater thanabout 150 (g· in)/in² and/or greater than about 175 (g· in)/in² and/orless than about 500 (g· in)/in² and/or less than about 400 (g· in)/in²and/or less than about 350 (g· in)/in² and/or less than about 300 (g·in)/in² and/or from about 40 (g· in)/in² to about 500 (g· in)/in² and/orfrom about 35 (g· in)/in² to about 400 (g· in)/in² and/or from about 50(g· in)/in² to about 350 (g· in)/in² and/or from about 75 (g· in)/in² toabout 300 (g· in)/in².

In one example of the fibrous structures of the present invention, thefibrous structure exhibits a VFS of greater than about 11 g/g and one ormore of the following: a Dry CD Tensile Modulus of less than about 1500g/cm and/or a Wet CD TEA of greater than about 35 (g· in)/in² and/or aWet MD TEA of greater than about 40 (g· in)/in².

The values of these properties associated with a fibrous structure aredetermined according to the respective test methods described herein.

To further illustrate the fibrous structures of the present invention,Table 2 sets forth certain properties of known and commerciallyavailable fibrous structures and a fibrous structure in accordance withthe present invention.

TABLE 2 Viva ® Viva ® Invention Property Duramax ® (Wetlaid) (Airlaid)Bounty ® Scott ® Sparkle ® Example Wet MD 377 21.4 34.5 22.4 16.7 14.890 TEA (g · in)/in² Wet CD 340 22.6 31.7 18.1 8.9 8.1 209 TEA (g ·in)/in² Dry CD Tensile 728 299 660 1844 1500 5900 400 Modulus g/cm VFSg/g 5.7 10.4 10.9 9.9 8 5.6 13Process for Making a Fibrous Structure

A nonlimiting example of a process for making a fibrous structureaccording to the present invention is represented in FIG. 10. Theprocess shown in FIG. 10 comprises the step of mixing a plurality ofsolid additives 14 with a plurality of filaments 12. In one example, thesolid additives 14 are wood pulp fibers, such as SSK fibers and/orEucalytpus fibers, and the filaments 12 are polypropylene filaments. Thesolid additives 14 may be combined with the filaments 12, such as bybeing delivered to a stream of filaments 12 from a hammermill 66 via asolid additive spreader 67 to form a mixture of filaments 12 and solidadditives 14. The filaments 12 may be created by meltblowing from ameltblow die 68. The mixture of solid additives 14 and filaments 12 arecollected on a collection device, such as a belt 70 to form a fibrousstructure 72. The collection device may be a patterned and/or moldedbelt that results in the fibrous structure exhibiting a surface pattern,such as a non-random, repeating pattern. The molded belt may have athree-dimensional pattern on it that gets imparted to the fibrousstructure 72 during the process.

In one example of the present invention, the fibrous structures are madeusing a die comprising at least one filament-forming hole, and/or 2 ormore and/or 3 or more rows of filament-forming holes from whichfilaments are spun. At least one row of holes contains 2 or more and/or3 or more and/or 10 or more filament-forming holes. In addition to thefilament-forming holes, the die comprises fluid-releasing holes, such asgas-releasing holes, in one example air-releasing holes, that provideattenuation to the filaments formed from the filament-forming holes. Oneor more fluid-releasing holes may be associated with a filament-forminghole such that the fluid exiting the fluid-releasing hole is parallel orsubstantially parallel (rather than angled like a knife-edge die) to anexterior surface of a filament exiting the filament-forming hole. In oneexample, the fluid exiting the fluid-releasing hole contacts theexterior surface of a filament formed from a filament-forming hole at anangle of less than 30° and/or less than 20° and/or less than 10° and/orless than 5° and/or about 0°. One or more fluid releasing holes may bearranged around a filament-forming hole. In one example, one or morefluid-releasing holes are associated with a single filament-forming holesuch that the fluid exiting the one or more fluid releasing holescontacts the exterior surface of a single filament formed from thesingle filament-forming hole. In one example, the fluid-releasing holepermits a fluid, such as a gas, for example air, to contact the exteriorsurface of a filament formed from a filament-forming hole rather thancontacting an inner surface of a filament, such as what happens when ahollow filament is formed.

In one example, the die comprises a filament-forming hole positionedwithin a fluid-releasing hole. The fluid-releasing hole 74 may beconcentrically or substantially concentrically positioned around afilament-forming hole 76 such as is shown in FIG. 11.

In another example, the die comprises filament-forming holes andfluid-releasing holes arranged to produce a plurality of filaments thatexhibit a broader range of filament diameters than knownfilament-forming hole dies, such as knife-edge dies. For example, asshown in FIG. 12, a fibrous structure made by a known knife-edge dieproduces a fibrous structure comprising filaments having a narrowerdistribution of average filament diameters than a fibrous structure madeby a die according to the present invention, as shown in FIG. 13. As isevidenced by FIG. 13, the fibrous structure made by a die according tothe present invention may comprise filaments that exhibit an averagefilament diameter of less than 1 μm. Such filaments are not seen in thefibrous structure made by the known knife-edge die as shown in FIG. 12.

After the fibrous structure 72 has been formed on the collection device,the fibrous structure 72 may be subjected to post-processing operationssuch as embossing, thermal bonding, tuft-generating operations,moisture-imparting operations, and surface treating operations to form afinished fibrous structure. One example of a surface treating operationthat the fibrous structure may be subjected to is the surfaceapplication of an elastomeric binder, such as ethylene vinyl acetate(EVA), latexes, and other elastomeric binders. Such an elastomericbinder may aid in reducing the lint created from the fibrous structureduring use by consumers. The elastomeric binder may be applied to one ormore surfaces of the fibrous structure in a pattern, especially anon-random repeating pattern, or in a manner that covers orsubstantially covers the entire surface(s) of the fibrous structure.

In one example, the fibrous structure 72 and/or the finished fibrousstructure may be combined with one or more other fibrous structures. Forexample, another fibrous structure, such as a filament-containingfibrous structure, such as a polypropylene filament fibrous structuremay be associated with a surface of the fibrous structure 72 and/or thefinished fibrous structure. The polypropylene filament fibrous structuremay be formed by meltblowing polypropylene filaments (filaments thatcomprise a second polymer that may be the same or different from thepolymer of the filaments in the fibrous structure 72) onto a surface ofthe fibrous structure 72 and/or finished fibrous structure. In anotherexample, the polypropylene filament fibrous structure may be formed bymeltblowing filaments comprising a second polymer that may be the sameor different from the polymer of the filaments in the fibrous structure72 onto a collection device to form the polypropylene filament fibrousstructure. The polypropylene filament fibrous structure may then becombined with the fibrous structure 72 or the finished fibrous structureto make a two-ply fibrous structure—three-ply if the fibrous structure72 or the finished fibrous structure is positioned between two plies ofthe polypropylene filament fibrous structure like that shown in FIG. 5for example. The polypropylene filament fibrous structure may bethermally bonded to the fibrous structure 72 or the finished fibrousstructure via a thermal bonding operation.

In yet another example, the fibrous structure 72 and/or finished fibrousstructure may be combined with a filament-containing fibrous structuresuch that the filament-containing fibrous structure, such as apolysaccharide filament fibrous structure, such as a starch filamentfibrous structure, is positioned between two fibrous structures 72 ortwo finished fibrous structures like that shown in FIG. 6 for example.

The process for making fibrous structure 72 may be close coupled (wherethe fibrous structure is convolutedly wound into a roll prior toproceeding to a converting operation) or directly coupled (where thefibrous structure is not convolutedly wound into a roll prior toproceeding to a converting operation) with a converting operation toemboss, print, deform, surface treat, or other post-forming operationknown to those in the art. For purposes of the present invention, directcoupling means that the fibrous structure 72 can proceed directly into aconverting operation rather than, for example, being convolutedly woundinto a roll and then unwound to proceed through a converting operation.

The process of the present invention may include preparing individualrolls of fibrous structure and/or sanitary tissue product comprisingsuch fibrous structure(s) that are suitable for consumer use. Thefibrous structure may be contacted by a bonding agent (such as anadhesive and/or dry strength agent), such that the ends of a roll ofsanitary tissue product according to the present invention comprise suchadhesive and/or dry strength agent.

The process may further comprise contacting an end edge of a roll offibrous structure with a material that is chemically different from thefilaments and fibers, to create bond regions that bond the fiberspresent at the end edge and reduce lint production during use. Thematerial may be applied by any suitable process known in the art.Nonlimiting examples of suitable processes for applying the materialinclude non-contact applications, such as spraying, and contactapplications, such as gravure roll printing, extruding, surfacetransferring. In addition, the application of the material may occur bytransfer from contact of a log saw and/or perforating blade containingthe material since, for example, the perforating operation, an edge ofthe fibrous structure that may produce lint upon dispensing a fibrousstructure sheet from an adjacent fibrous structure sheet may be created.

Nonlimiting Example of Process for Making a Fibrous Structure of thePresent Invention:

A 47.5%:47.5%:5% blend of Exxon-Mobil PP3546 polypropylene: SunocoCP200VM polypropylene: Polyvel S-1416 wetting agent is dry blended, toform a melt blend. The melt blend is heated to 475° F. through a meltextruder. A 10″ wide Biax 12 row spinnerette with 192 nozzles percross-direction inch, commercially available from Biax FiberfilmCorporation, is utilized. 32 nozzles per cross-direction inch of the 192nozzles have a 0.018″ inside diameter while the remaining nozzles aresolid, i.e. there is no opening in the nozzle. Approximately 0.17 gramsper hole per minute (ghm) of the melt blend is extruded from the opennozzles to form meltblown filaments from the melt blend. Approximately200 SCFM of compressed air is heated such that the air exhibits atemperature of 395° F. at the spinnerette. Approximately 175grams/minute of Koch 4825 semi-treated SSK pulp is defibrillated througha hammermill to form SSK wood pulp fibers (solid additive). 330 SCFM ofair at 85-90° F. and 85% relative humidity (RH) is drawn into thehammermill and carries the pulp fibers to a solid additive spreader. Thesolid additive spreader turns the pulp fibers and distributes the pulpfibers in the cross-direction such that the pulp fibers are injectedinto the meltblown filaments in a perpendicular fashion through a 2″×10″cross-direction (CD) slot. A forming box surrounds the area where themeltblown filaments and pulp fibers are commingled. This forming box isdesigned to reduce the amount of air allowed to enter or escape fromthis commingling area; however, there is a 2″×12″ opening in the bottomof the forming box designed to permit additional cooling air to enter. Aforming vacuum pulls air through a forming fabric thus collecting thecommingled meltblown filaments and pulp fibers to form a fibrousstructure. The forming vacuum is adjusted until an additional 400 SCFMof room air is drawn into the slot in the forming box. The fibrousstructure formed by this process comprises about 75% by dry fibrousstructure weight of pulp and about 25% by dry fibrous structure weightof meltblown filaments.

As shown in FIG. 14, the solid additive spreader 78 has an inlet 80 andan exit 82. Any suitable material known in the art may be used to makethe spreader 78. Nonlimiting examples of suitable materials includenon-conductive materials. For example, stainless steel and/or sheetmetal may be used to fabricate the spreader 78. A pulp and air mixture84 created in the hammermill (not shown) enters the spreader 78 througha duct (not shown) connecting the hammermill and spreader 78 at greaterthan about 8,000 fpm velocity and/or greater than about 14,000 fpm. Theinlet 80 is tilted at an angle α at approximately 5° upstream fromperpendicular of the exit 82. The exit 82 of the solid additive spreader78 has a height H in the range of about 2.54 cm (1 inch) to about 25.40cm (10 inches). The width W of the exit 82 is from about 1.27 cm (0.5inch) to about 10.16 cm (4 inches). Typically the width W of the exit 82is about 5.08 cm (2 inches). The length L of the spreader 78 is fromabout 60.96 cm (24 inches) to about 243.84 cm (96 inches) and/or fromabout 91.44 cm (36 inches) to about 182.88 cm (72 inches) and/or fromabout 121.92 cm (48 inches) to about 152.40 cm (60 inches). A taperingof the height H of the spreader 78 occurs from the inlet end 86 to theexit end 88 to continually accelerate the pulp and air mixture 84. Thistapering is from about 10.16 cm (4 inches) in height at the inlet 80 toabout 5.08 cm (2 inches) in height at the exit 82. However, the spreader78 may incorporate other similar taperings. The inlet end 86 of thespreader 78 has a semi-circular arc from the top view with a radius offrom about 7.62 cm (3 inches) to about 50.80 cm (20 inches) and/or fromabout 12.70 cm (5 inches) to about 25.40 cm (10 inches). As shown inFIG. 15, multiple semi-circular arcs can be assembled to produce thedesired spreader width. Each semi-circular arc would comprise its owninlet 80 centered in each of these semi-circular arcs.

Optionally, a meltblown layer of the meltblown filaments can be added toone or both sides of the above formed fibrous structure. This additionof the meltblown layer can help reduce the lint created from the fibrousstructure during use by consumers and is preferably performed prior toany thermal bonding operation of the fibrous structure. The meltblownfilaments for the exterior layers can be the same or different than themeltblown filaments used on the opposite layer or in the centerlayer(s).

The fibrous structure may be convolutedly wound to form a roll offibrous structure. The end edges of the roll of fibrous structure may becontacted with a material to create bond regions.

Test Methods

Unless otherwise indicated, all tests described herein including thosedescribed under the Definitions section and the following test methodsare conducted on samples that have been conditioned in a conditionedroom at a temperature of 73° F.±4° F. (about 23° C.±2.2° C.) and arelative humidity of 50%±10% for 2 hours prior to the test. Samplesconditioned as described herein are considered dry samples (such as “dryfibrous structures”) for purposes of this invention. Further, all testsare conducted in such conditioned room.

A. Pore Volume Distribution Test Method

Pore Volume Distribution measurements are made on a TRI/Autoporosimeter(TRI/Princeton Inc. of Princeton, N.J.). The TRI/Autoporosimeter is anautomated computer-controlled instrument for measuring pore volumedistributions in porous materials (e.g., the volumes of different sizepores within the range from 1 to 1000 □μm effective pore radii).Complimentary Automated Instrument Software, Release 2000.1, and DataTreatment Software, Release 2000.1 is used to capture, analyze andoutput the data. More information on the TRI/Autoporosimeter, itsoperation and data treatments can be found in The Journal of Colloid andInterface Science 162 (1994), pgs 163-170, incorporated here byreference.

As used in this application, determining Pore Volume Distributioninvolves recording the increment of liquid that enters a porous materialas the surrounding air pressure changes. A sample in the test chamber isexposed to precisely controlled changes in air pressure. The size(radius) of the largest pore able to hold liquid is a function of theair pressure. As the air pressure increases (decreases), different sizepore groups drain (absorb) liquid. The pore volume of each group isequal to this amount of liquid, as measured by the instrument at thecorresponding pressure. The effective radius of a pore is related to thepressure differential by the following relationship.Pressure differential=[(2)γ cos Θ]/effective radiuswhere γ=liquid surface tension, and Θ=contact angle.

Typically pores are thought of in terms such as voids, holes or conduitsin a porous material. It is important to note that this method uses theabove equation to calculate effective pore radii based on the constantsand equipment controlled pressures. The above equation assumes uniformcylindrical pores. Usually, the pores in natural and manufactured porousmaterials are not perfectly cylindrical, nor all uniform. Therefore, theeffective radii reported here may not equate exactly to measurements ofvoid dimensions obtained by other methods such as microscopy. However,these measurements do provide an accepted means to characterize relativedifferences in void structure between materials.

The equipment operates by changing the test chamber air pressure inuser-specified increments, either by decreasing pressure (increasingpore size) to absorb liquid, or increasing pressure (decreasing poresize) to drain liquid. The liquid volume absorbed (drained) at eachpressure increment is the cumulative volume for the group of all poresbetween the preceding pressure setting and the current setting.

In this application of the TRI/Autoporosimeter, the liquid is a 0.2weight % solution of octylphenoxy polyethoxy ethanol (Triton X-100 fromUnion Carbide Chemical and Plastics Co. of Danbury, Conn.) in distilledwater. The instrument calculation constants are as follows: p(density)=1 g/cm³; γ (surface tension)=31 dynes/cm; cos Θ=1. A 0.22 μmMillipore Glass Filter (Millipore Corporation of Bedford, Mass.; Catalog#GSWP09025) is employed on the test chamber's porous plate. A plexiglassplate weighing about 24 g (supplied with the instrument) is placed onthe sample to ensure the sample rests flat on the Millipore Filter. Noadditional weight is placed on the sample.

The remaining user specified inputs are described below. The sequence ofpore sizes (pressures) for this application is as follows (effectivepore radius in μm): 1, 2.5, 5, 10, 15, 20, 30, 40, 50, 60, 70, 80, 90,100, 120, 140, 160, 180, 200, 225, 250, 275, 300, 350, 400, 500, 600,800, 1000. This sequence starts with the sample dry, saturates it as thepore settings increase (typically referred to with respect to theprocedure and instrument as the 1^(st) absorption).

In addition to the test materials, a blank condition (no sample betweenplexiglass plate and Millipore Filter) is run to account for any surfaceand/or edge effects within the chamber. Any pore volume measured forthis blank run is subtracted from the applicable pore grouping of thetest sample. This data treatment can be accomplished manually or withthe available TRI/Autoporosimeter Data Treatment Software, Release2000.1.

Percent (%)Total Pore Volume is a percentage calculated by taking thevolume of fluid in the specific pore radii range divided by the TotalPore Volume. The TRI/Autoporosimeter outputs the volume of fluid withina range of pore radii. The first data obtained is for the “2.5 micron”pore radii which includes fluid absorbed between the pore sizes of 1 to2.5 micron radius. The next data obtained is for “5 micron” pore radii,which includes fluid absorbed between the 2.5 micron and 5 micron radii,and so on. Following this logic, to obtain the volume held within therange of 101-200 micron radii, one would sum the volumes obtained in therange titled “120 micron”, “140 micron”, “160 micron”, “180 micron”, andfinally the “200 micron” pore radii ranges. For example, % Total PoreVolume 101-200 micron pore radii=(volume of fluid between 101-200 micronpore radii)/Total Pore Volume.

B. Horizontal Full Sheet (HFS) Test Method

The Horizontal Full Sheet (HFS) test method determines the amount ofdistilled water absorbed and retained by a fibrous structure of thepresent invention. This method is performed by first weighing a sampleof the fibrous structure to be tested (referred to herein as the “dryweight of the sample”), then thoroughly wetting the sample, draining thewetted sample in a horizontal position and then reweighing (referred toherein as “wet weight of the sample”). The absorptive capacity of thesample is then computed as the amount of water retained in units ofgrams of water absorbed by the sample. When evaluating different fibrousstructure samples, the same size of fibrous structure is used for allsamples tested.

The apparatus for determining the HFS capacity of fibrous structurescomprises the following:

1) An electronic balance with a sensitivity of at least ±0.01 grams anda minimum capacity of 1200 grams. The balance should be positioned on abalance table and slab to minimize the vibration effects offloor/benchtop weighing. The balance should also have a special balancepan to be able to handle the size of the sample tested (i.e.; a fibrousstructure sample of about 11 in. (27.9 cm) by 11 in. (27.9 cm)). Thebalance pan can be made out of a variety of materials. Plexiglass is acommon material used.

2) A sample support rack (FIG. 16) and sample support rack cover (FIG.17) is also required. Both the rack and cover are comprised of alightweight metal frame, strung with 0.012 in. (0.305 cm) diametermonofilament so as to form a grid as shown in FIG. 16. The size of thesupport rack and cover is such that the sample size can be convenientlyplaced between the two.

The HFS test is performed in an environment maintained at 23±1° C. and50±2% relative humidity. A water reservoir or tub is filled withdistilled water at 23±1° C. to a depth of 3 inches (7.6 cm).

Eight samples of a fibrous structure to be tested are carefully weighedon the balance to the nearest 0.01 grams. The dry weight of each sampleis reported to the nearest 0.01 grams. The empty sample support rack isplaced on the balance with the special balance pan described above. Thebalance is then zeroed (tared). One sample is carefully placed on thesample support rack. The support rack cover is placed on top of thesupport rack. The sample (now sandwiched between the rack and cover) issubmerged in the water reservoir. After the sample is submerged for 60seconds, the sample support rack and cover are gently raised out of thereservoir.

The sample, support rack and cover are allowed to drain horizontally for120±5 seconds, taking care not to excessively shake or vibrate thesample. While the sample is draining, the rack cover is carefullyremoved and all excess water is wiped from the support rack. The wetsample and the support rack are weighed on the previously tared balance.The weight is recorded to the nearest 0.01 g. This is the wet weight ofthe sample.

The gram per fibrous structure sample absorptive capacity of the sampleis defined as (wet weight of the sample−dry weight of the sample). Thehorizontal absorbent capacity (HAC) is defined as: absorbentcapacity=(wet weight of the sample−dry weight of the sample)/(dry weightof the sample) and has a unit of gram/gram.

C. Vertical Full Sheet (VFS) Test Method

The Vertical Full Sheet (VFS) test method determines the amount ofdistilled water absorbed and retained by a fibrous structure of thepresent invention. This method is performed by first weighing a sampleof the fibrous structure to be tested (referred to herein as the “dryweight of the sample”), then thoroughly wetting the sample, draining thewetted sample in a vertical position and then reweighing (referred toherein as “wet weight of the sample”). The absorptive capacity of thesample is then computed as the amount of water retained in units ofgrams of water absorbed by the sample. When evaluating different fibrousstructure samples, the same size of fibrous structure is used for allsamples tested.

The apparatus for determining the VFS capacity of fibrous structurescomprises the following:

1) An electronic balance with a sensitivity of at least ±0.01 grams anda minimum capacity of 1200 grams. The balance should be positioned on abalance table and slab to minimize the vibration effects offloor/benchtop weighing. The balance should also have a special balancepan to be able to handle the size of the sample tested (i.e.; a fibrousstructure sample of about 11 in. (27.9 cm) by 11 in. (27.9 cm)). Thebalance pan can be made out of a variety of materials. Plexiglass is acommon material used.

2) A sample support rack (FIG. 16) and sample support rack cover (FIG.17) is also required. Both the rack and cover are comprised of alightweight metal frame, strung with 0.012 in. (0.305 cm) diametermonofilament so as to form a grid as shown in FIG. 16. The size of thesupport rack and cover is such that the sample size can be convenientlyplaced between the two.

The VFS test is performed in an environment maintained at 23±1° C. and50±2% relative humidity. A water reservoir or tub is filled withdistilled water at 23±1° C. to a depth of 3 inches (7.6 cm).

Eight 19.05 cm (7.5 inch)×19.05 cm (7.5 inch) to 27.94 cm (11inch)×27.94 cm (11 inch) samples of a fibrous structure to be tested arecarefully weighed on the balance to the nearest 0.01 grams. The dryweight of each sample is reported to the nearest 0.01 grams. The emptysample support rack is placed on the balance with the special balancepan described above. The balance is then zeroed (tared). One sample iscarefully placed on the sample support rack. The support rack cover isplaced on top of the support rack. The sample (now sandwiched betweenthe rack and cover) is submerged in the water reservoir. After thesample is submerged for 60 seconds, the sample support rack and coverare gently raised out of the reservoir.

The sample, support rack and cover are allowed to drain vertically for60±5 seconds, taking care not to excessively shake or vibrate thesample. While the sample is draining, the rack cover is carefullyremoved and all excess water is wiped from the support rack. The wetsample and the support rack are weighed on the previously tared balance.The weight is recorded to the nearest 0.01 g. This is the wet weight ofthe sample.

The procedure is repeated for with another sample of the fibrousstructure, however, the sample is positioned on the support rack suchthat the sample is rotated 90° compared to the position of the firstsample on the support rack.

The gram per fibrous structure sample absorptive capacity of the sampleis defined as (wet weight of the sample−dry weight of the sample). Thecalculated VFS is the average of the absorptive capacities of the twosamples of the fibrous structure.

D. Wet MD TEA, Wet CD TEA, Dry CD Tensile Modulus (“Tangent Modulus”)Test Methods

The Wet MD TEA, Wet CD TEA and Dry CD Tensile Modulus of a fibrousstructure are all determined using a Thwing Albert EJA Tensile Tester. A2.54 cm (1 inch) wide strip of the fibrous structure to be tested isplaced in the grips of the Tensile Tester at a gauge length of 10.16 cm(4 inches). The Crosshead Speed of the Tensile Tester is set at 10.16cm/min (4 inches/min) and the Break Sensitivity is set at 20 g. Eight(8) samples are run on the Tensile Tester and an average of therespective Wet MD TEA, Wet CD TEA values from the 8 samples is reportedas the Wet MD TEA value and the Wet CD TEA. The Dry CD Tensile Modulusis reported as the average of the Dry CD Tensile Modulus from the 8samples measured at 15 g/cm.

E. Basis Weight Test Method

Basis weight is measured by preparing one or more samples of a certainarea (m²) and weighing the sample(s) of a fibrous structure according tothe present invention and/or a paper product comprising such fibrousstructure on a top loading balance with a minimum resolution of 0.01 g.The balance is protected from air drafts and other disturbances using adraft shield. Weights are recorded when the readings on the balancebecome constant. The average weight (g) is calculated and the averagearea of the samples (m²). The basis weight (g/m²) is calculated bydividing the average weight (g) by the average area of the samples (m²).

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention. To the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A process for making a fibrous structure, the process comprising the steps of: a. providing a die comprising three or more rows of three or more filament-forming holes; b. supplying at least a first polymer to the die; c. producing a plurality of filaments comprising the first polymer from the die; d. combining the filaments with solid additives to form a mixture; and e. collecting the mixture on a belt to produce a fibrous structure.
 2. The process according to claim 1 wherein at least one row of the three or more rows comprises ten or more filament-forming holes.
 3. The process according to claim 1 wherein one or more fluid-releasing holes are associated with a filament-forming hole.
 4. The process according to claim 3 wherein more than one fluid-releasing holes is associated with a filament-forming hole.
 5. The process according to claim 3 wherein at least one of the one or more fluid-releasing holes is concentrically positioned around one filament-forming hole.
 6. The process according to claim 1 wherein the first polymer comprises a synthetic polymer.
 7. The process according to claim 6 wherein the synthetic polymer is selected from the group consisting of: polyvinyl alcohol, polyvinyl alcohol derivatives, polyesters, nylons, polyolefins, polylactic acids, polyhydroxyalkanoates, polycaprolactones and mixtures thereof.
 8. The process according to claim 7 wherein the synthetic polymer comprises a polyolefin.
 9. The process according to claim 8 wherein the polyolefin comprises polypropylene.
 10. The process according to claim 7 wherein the synthetic polymer is selected from the group consisting of: polylactic acids, polyhydroxyalkanoates, polycaprolactones and mixtures thereof.
 11. The process according to claim 1 wherein the first polymer comprises a natural polymer.
 12. The process according to claim 11 wherein the natural polymer is selected from the group consisting of: starch, starch derivatives, cellulose, cellulose derivatives, hemicellulose, hemicellulose derivatives and mixtures thereof.
 13. The process according to claim 1 wherein the solid additives comprise fibers.
 14. The process according to claim 13 wherein the fibers comprise wood pulp fibers.
 15. The process according to claim 1 wherein the solid additives are combined with the plurality of filaments by a solid additive spreader.
 16. The process according to claim 1 wherein the process further comprises the step of: f. contacting a surface of the fibrous structure with a plurality of filaments comprising a second polymer.
 17. The process according to claim 16 wherein the plurality of filaments comprising the second polymer are in the form of a second fibrous structure.
 18. The process according to claim 16 wherein the second polymer is the same as the first polymer.
 19. The process according to claim 3 wherein a fluid released by the fluid-releasing holes comprises air.
 20. The process according to claim 1 wherein the fibrous structure exhibits a pore volume distribution such that greater than about 40% of the total pore volume present in the fibrous structure exists in pores of radii of from about 121 μm to about 200 μm.
 21. The process according to claim 1 wherein the process further comprises the step of subjecting the fibrous structure to a thermal bonding operation.
 22. The process according to claim 1 wherein the process is directly coupled to a post-processing operation.
 23. The process according to claim 1 wherein the process is closely coupled to a post-processing operation.
 24. A process for making a fibrous structure, the process comprising the steps of: a. providing a die comprising three or more rows of three or more filament-forming holes; b. supplying a polyolefin polymer to the die; c. producing a plurality of filaments comprising the polyolefin polymer from the die; d. combining the filaments with wood pulp fibers to form a mixture; and e. collecting the mixture on a belt to produce a fibrous structure. 